Thermal and/or fire resistant panel, a mounting assembly, and a kit

ABSTRACT

Disclosed herein is a thermal and/or fire resistant panel comprising: a panel body comprising a fire resistant composition, wherein the fire resistant composition comprises: a silane cross-linked hybrid inorganic polymer; and a siloxane.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a US national phase application of internationalpatent application No. PCT/AU2019/050474 filed on May 17, 2019, whichclaims priority to Australian patent application No. 2018901758 filed onMay 19, 2018, the disclosures of each of which are fully incorporatedherein by reference in their entireties.

FIELD OF THE INVENTION

The present technology relates generally to thermal and/or fireinsulation material, thermal and/or fire resistant panels, insulationassemblies and kits for their assembly. Embodiments of the technologyfind particularly effective application in inhibiting heat and/or firetransfer in marine applications such as in seagoing ships and fastferries but the technology is generally suitable for any building orland going or flying vehicle, wherein thermal and/or fire resistantpanels, systems and assemblies are installed to inhibit heat transferand/or fire transfer from one side of a partition, wall, deck or floor,to the other.

BACKGROUND OF THE INVENTION

Fires can be devastating in seagoing vessels or other vehicles, where,for one reason or another, people onboard cannot quickly or easily moveto safety via egress or movement to some other area of the vehicle orvessel. Oftentimes in emergency situations there are multiple problemsthat simultaneously become of relevance, such as engine fire, galleyfire, hull breach and structure buckling which inhibits operation oflifeboat davits and free passenger movement around the vessel throughbulkheads and other areas. It is therefore important to delay, for aslong as possible, the transfer of heat from one or more rooms in which afire may have broken out, to other areas of the vehicle or vessel.

It is also useful for a seagoing vessel or other land-going or flyingvehicle to have a light structure, so as to transport its cargo orpassengers as efficiently as possible, and to keep it afloat for as longas possible in an emergency situation.

Known thermal and fire insulation materials come with a heavy weightpenalty, in particular since they are installed with a high wrap factor.They are formed around the contours of the seagoing vessel or vehicle,including around strengthening and stiffening beams and channels.

There are several guidelines and standards with which designers of atleast some parts of some types of seagoing vessels are required to atleast consider or comply, including A60-class structural fire protectionsystem; B15 Partitions and ceilings; H60-class structural fireprotection systems; H120 Structural fire protection systems; N30structural fire protection systems; SOLAS (Safety of Life at Sea); HSCCode (High Speed Craft); ISO fire standards; buildings fire standards;aviation fire standards; and FTP (Fire Test Procedure Code). As anexample of a relevant consideration in at least one guideline orstandard, the presence of high levels of organic compounds isundesirable or banned. In some other guidelines or standards it isprescribed that on one side of a barrier, when there has been presentfor one hour a heat of about 945 Celsius, the temperature readingaveraged over five evenly-spaced thermocouples mounted on the other sideshould be less than 140 Celsius.

The present invention seeks to provide a new insulation material and/orthermal and/or fire resistant panel assembly and/or kit which seeks toameliorate one or more of the above disadvantages or at least make a newalternative.

SUMMARY OF THE INVENTION

In a first aspect of the invention, there is provided a thermal and/orfire resistant panel comprising:

a panel body comprising a fire resistant composition, wherein the fireresistant composition comprises:

a silane cross-linked hybrid inorganic polymer; and

a siloxane.

In an embodiment, the panel body has at least one surface lined,treated, coated, or impregnated with the fire resistant composition.

In an embodiment, the silane cross linked hybrid inorganic polymer is ofFormula I:R_(m)[M₂O]_(x)[Al₂O₃]_(y)[SiO₂]_(z)X_(q).PH₂O   Formula Iwherein R represents an organic functional group; M is an alkali metal;X is selected from chlorine and fluorine; m is >0; q is ≥0; x is from 1to 1.6; y is from 1.0; x/y is from 1.0 to 1.6; z is from 3 to 65; z/y is≥1.0; and P is from 3 to 5.

In one form of the above embodiment, M is an alkali metal selected fromthe group consisting of Na, K, Li, or mixtures thereof.

In one form of the above embodiment, the organic functional group R is asilane of the form R¹ _(n)SiO_(4-n), wherein R¹ represents an organicmoiety and n is selected from 1, 2, or 3. Preferably, the silane is aglycidyl silane or an amino silane. More preferably, the silane is aglycidyl silane.

In an embodiment, a ratio of Al to alkali metal in the fire resistantcomposition is from about 4:13 to about 3:5 when measured as metakaolinand alkali metal silicate respectively.

In an embodiment, the composition comprises from about 20 wt % to about30 wt % Al when measured as metakaolin.

In an embodiment, the composition comprises from about 50 wt % to about65 wt % alkali metal when measured as alkali metal silicate.

In an embodiment, the composition comprises from about 1 wt % up toabout 10 wt % silane cross-linking agent. Preferably, the compositioncomprises from about 2 wt % silane cross-linking agent. More preferably,the composition comprises from about 3 wt % silane cross-linking agent.Most preferably, the composition comprises from about 4 wt % silanecross-linking agent. Alternatively or additionally, it is preferred thatthe composition comprises up to about 9 wt % silane cross-linking agent.More preferably, the composition comprises up to about 8 wt % silanecross-linking agent. Most preferably, the composition comprises up toabout 7 wt % silane cross-linking agent. In one example, the compositioncomprises 5 wt %±1 wt % silane cross-linking agent.

In an embodiment, the composition comprises from about 0.5 wt % to about5 wt % siloxane. Preferably, the composition comprises from about 1.0 wt% siloxane. More preferably, the composition comprises from about 1.5 wt% siloxane. Most preferably, the composition comprises from about 2 wt %siloxane. Alternatively or additionally, it is preferred that thecomposition comprises up to about 4.5 wt % siloxane. More preferably,the composition comprises up to about 4.0 wt % siloxane. Mostpreferably, the composition comprises up to about 3.5 wt % siloxane. Inone example, the composition comprises 2.5 wt %±0.5 wt % siloxane.

In an embodiment, the thermal and/or fire resistant panel is a panel ofa refractory material. Preferably, the panel comprises, consists of, orconsists essentially of one or more refractory materials. In one form ofthis embodiment, the thermal and/or fire resistant panel comprises lessthan 20 wt % organic matter. Preferably, the panel comprises less than10 wt % organic matter. Most preferably, the panel containssubstantially no organic matter and/or organic compounds. Bysubstantially no organic matter and/or organic compounds it is meantless than 2 wt %, preferably less than 1 wt %, and most preferably lessthan 0.5 wt %. In still further forms of this embodiment, the thermaland/or fire resistant panel does not include wood.

In an embodiment, the panel body is laminated with a layer of a wovenmaterial comprising the fire resistant composition. Preferably, thelayer of the woven material is selected from the group consisting of:glass fibre, carbon cloth, basalt cloth and steel mesh.

In an embodiment thermal and/or fire resistant panel is in the form of aboard. In alternative embodiments the thermal insulation panel is afibre blanket. In these alternative embodiments the fibre blankets maybe reinforced with battens or other strengthening supports on thesurface or within the blanket itself to provide a panel-like thermalinsulating element.

In an embodiment, a thermal and/or fire resistant panel is lined with oris impregnated with an acoustic attenuation material. In forms of thisembodiment, the acoustic attenuation material is in the form of acontoured surface on one side, or a heavy layer sandwiched within thethermal and/or fire resistant panel. Preferably, the heavy layer isflexible and/or mounted in a foam such as an intumescent foam, or thelike. More preferably, the acoustic attenuation material is the foam.

In an embodiment the dimensions of the thermal and/or fire resistantpanel are stable under the effects of heat in the range of 0 to 1100° C.However, it will be appreciated that the thermal and/or fire resistantpanel may be dimensionally heat stable under higher temperatures.

In an embodiment, the panel body is a thermal insulating blank, such asa blank of refractory material. In one form of this embodiment, theblank is a compressed fibre board of refractory fibres. It is preferredthat the blank of refractory material comprises: refractories and/orfibres and/or amorphous alkaline-earth-silicates 0.1-90 wt %; Perlite0.1-20 wt %, colloidal silica 0.1-20 wt %, and starch 0.1-20%.

Other thermal insulating blank compositions are contemplated, includingmixtures in various proportions of polycrystalline wools, amorphoussilica, water and polyacrylamide.

In forms of the above embodiment, the thermal insulating blank has athermal conductivity value of less than 0.3 W/m·K at temperatures at1000° C. or less.

In an embodiment, the fire resistant panel further comprises a layer ofa composite material including any one or more of the group consistingof: woven mat, non-woven mat, fibres, felt and fabric. Preferably thelayer of composite material comprises the fire resistant composition.

In an embodiment, the fire resistant panel further comprises a vapourbarrier layer on at least one or more faces of the panel body. It ispreferred that the vapour barrier layer is selected from the groupconsisting of aluminium foil, paint, or Venture Tape (a product of the3M company).

In an embodiment the fire resistant panel has dimensions of up to about1200 mm×up to about 2400 mm×up to about 25 mm. Other dimensions arecontemplated. However, this panel size is useful for managing thestresses likely to be experienced by the fire resistant panel.

In a second aspect of the invention, there is provided a method ofpreparing a fire resistant panel comprising (such as the fire resistantpanel according to the first aspect of the invention and embodimentsthereof):

-   -   applying a resin of a fire resistant composition to a surface of        a panel body; and    -   curing the resin to form a fire resistant panel including a fire        resistant composition comprising:    -   a silane cross-linked hybrid inorganic polymer; and    -   a siloxane.

In an embodiment, the resin comprises:

-   -   a hybrid inorganic polymer;    -   a silane;    -   a siloxane.

In an embodiment, the resin further comprises an alkali metal silicate.

In an embodiment, the silane cross linked hybrid inorganic polymer is ofFormula I. Preferably, M is an alkali metal selected from the groupconsisting of such sodium, potassium, lithium, or mixtures thereof.

In one form of the above embodiment, the organic functional group R is asilane of the form R¹ _(n)SiO_(4-n), wherein R¹ represents an organicmoiety and n is selected from 1, 2, or 3. Preferably, the silane is aglycidyl silane or an amino silane. More preferably, the silane is aglycidyl silane.

In an embodiment, a ratio of Al to alkali metal in the resin and/or fireresistant composition is from about 4:13 to about 3:5 when measured asmetakaolin and alkali metal silicate respectively.

In an embodiment, the resin and/or fire resistant composition comprisesfrom about 20 wt % to about 30 wt % Al when measured as metakaolin.

In an embodiment, the resin and/or fire resistant composition comprisesfrom about 50 wt % to about 65 wt % alkali metal when measured as alkalimetal silicate.

In an embodiment, the resin and/or fire resistant composition comprisesfrom about 1 wt % up to about 10 wt % silane cross-linking agent.Preferably, the resin and/or fire resistant composition comprises fromabout 2 wt % silane cross-linking agent. More preferably, the resinand/or fire resistant composition comprises from about 3 wt % silanecross-linking agent. Most preferably, the resin and/or fire resistantcomposition comprises from about 4 wt % silane cross-linking agent.Alternatively or additionally, it is preferred that the resin and/orfire resistant composition comprises up to about 9 wt % silanecross-linking agent. More preferably, the resin and/or fire resistantcomposition comprises up to about 8 wt % silane cross-linking agent.Most preferably, the resin and/or fire resistant composition comprisesup to about 7 wt % silane cross-linking agent. In one example, thecomposition resin and/or fire resistant composition 5 wt %+1 wt % silanecross-linking agent.

In an embodiment, the resin and/or fire resistant composition comprisesfrom about 0.5 wt % to about 5 wt % siloxane. Preferably, the resinand/or fire resistant composition comprises from about 1.0 wt %siloxane. More preferably, the resin and/or fire resistant compositioncomprises from about 1.5 wt % siloxane. Most preferably, the resinand/or fire resistant composition comprises from about 2 wt % siloxane.Alternatively or additionally, it is preferred that the resin and/orfire resistant composition comprises up to about 4.5 wt % siloxane. Morepreferably, the resin and/or fire resistant composition comprises up toabout 4.0 wt % siloxane. Most preferably, the resin and/or fireresistant composition comprises up to about 3.5 wt % siloxane. In oneexample, the resin and/or fire resistant composition comprises 2.5 wt%±0.5 wt % siloxane.

In an embodiment, the thermal and/or fire resistant panel is a panel ofa refractory material. Preferably, the panel comprises, consists of, orconsists essentially of one or more refractory materials. In one form ofthis embodiment, the thermal and/or fire resistant panel comprises lessthan 20 wt % organic matter (i.e. substantially inorganic). Preferably,the panel comprises less than 10 wt % organic matter. Most preferably,the panel contains substantially no organic matter and/or organiccompounds. By substantially no organic matter and/or organic compoundsit is meant less than 2 wt %, preferably less than 1 wt %, and mostpreferably less than 0.5 wt %. In still further forms of thisembodiment, the thermal and/or fire resistant panel does not includewood.

In a third aspect of the invention, there is provided the use of a resinin the preparation of a fire resistant panel (such as the fire resistantpanel according to the first aspect of the invention and embodimentsthereof, or a fire resistant panel produced according to the method ofthe second aspect of the invention and embodiments thereof).

In a fourth aspect of the invention, there is provided a kit forinstalling a thermal and/or fire insulation panel assembly on a wall ormounting surface, the kit comprising:

-   -   one or more thermal and/or fire resistant panels according to        the first aspect of the invention or embodiments thereof, or        produced according to the method of the third aspect of the        invention;    -   a locating frame for receiving the thermal and/or fire resistant        panels; and    -   one or more thermal and/or fire insulation panel retainers        configured to fasten to or otherwise mount onto the locating        frame.

In a fifth aspect of the invention, there is provided a thermal and/orfire resistant panel assembly comprising;

-   -   one or more thermal and/or fire resistant panels according to        the first aspect of the invention or embodiments thereof, or        produced according to the method of the third aspect of the        invention;    -   a locating frame configured to be mounted on a wall or other        surface, the locating frame receiving at least portions of the        one or more thermal and/or fire insulation panels thereon; and    -   one or more panel retainers fastened to or otherwise mounted on        the locating frame.

In an embodiment of the fourth or fifth aspects, the locating framecomprises a plurality of panel locating elements for locating at least aportion of the thermal and/or fire resistant panel(s).

In an embodiment of the fourth or fifth aspects, the locating frameincludes a plurality of frame elements, each including one or more panellocating elements.

In one form of this embodiment, each of the plurality of panel locatingelements is in the form of edge locating elements for receiving at leasta portion of an edge of the thermal and/or fire insulating panelsrelative to the locating frame and other adjacent thermal insulatingpanels.

In one form of this embodiment, each of the panel locating elementscomprises a recess for receiving a portion of a panel. Preferably, therecess is in the form of a shoulder against which a portion of the panelmay abut in use. More preferably, two shoulders are provided,spaced-apart from one another, on opposite sides of an elongate frameelement, to provide symmetry to facilitate ease of assembly. Mostpreferably, a landing is provided between the shoulders so as tofacilitate mounting of a retainer thereon. It is still further preferredthat the elongate frame element is a top-hat-on-a-top-hat section, thesection being formed by being rolled or press-braked. In one embodimentthe section is 0.45 mm thick stainless steel, for longevity in a marineenvironment, the spaces provided under the hats for thermal and/or fireinsulation. Advantageously there is a small contact patch relative tothe stand-off, so that thermal conductivity by conduction is reduced tothe mounting surface.

The top-hat-on-a-top-hat section in some embodiments provides rigidityfor support of panels but also a small contact patch with the mountingsurface (or the mounting spacers in some embodiments), to reduce thermaltransmission by conduction and to a lesser extent, radiation, from theshoulder of the frame elements to the mounting surface.

In one form of this embodiment, the one or more frame elements comprisesan integral mounting spacer for spacing the thermal and/or fireinsulating panel from the wall and/or ceiling on which the frame elementis mounted. Preferably, the integral spacer is in the form of a plinth.More preferably, the plinth is in the form of a top-hat channel sectionso as to be integral with the frame element. Still more preferably, informs in which the recess is in the form of a shoulder against which aportion of the panel may abut in use, the shoulder is mounted on theplinth and is integral therewith so as to provide a vapour seal.

In one form of this embodiment, the frame elements are elongate channelsections. Preferably, the frame elements are straight. However, arcuateor suitably contoured frame elements are contemplated depending on theapplication.

In various forms of the invention, there is provided a joiner whichjoins a plurality of elongate frame elements. The joiner may includerecesses for receiving the ends of the elongate frame elements. Thejoiner may be a cruciform with four orthogonal recesses to receive fourframe ends. Preferably, a gasket/seal is provided at edges or verticesof the frame elements to inhibit thermal leakage or smoke leakagethrough the assembly. The gasket/seal is configured to be mounted on thepanel faces and may be fastened thereon by at least one retainer.Preferably, the gasket/seal and/or retainer fasten to the joiner tofacilitate the seal.

In various forms, the gasket/seal is formed from an intumescent panelconstructed of organic thermal insulation material. In one embodimentthe seal is a disc of intumescent material of about 140 mm in diameter.The gasket may be impregnated paper.

In one embodiment of the fourth or fifth aspects, there is provided aseal which includes a disc of silica fibres.

In embodiments including one or more retainers, it is preferred that theretainers fasten or otherwise inter-engage with a respective frameelement.

In embodiments including one or more retainers, it is preferred that theone or more of the retainers are in the form of a disc retainerconfigured to retain the gasket seal onto one or more of the frameelements. The disc retainer preferably retains the panel directly bybeing mounted abutting thereagainst, and fastened to a frame element.

In embodiments including one or more retainers, it is preferred that theone or more of the retainers are in the form of an elongate strip whichabuts the panels along the edge and extends along the frame element andis fastened or otherwise interrogated therewith.

In embodiments including a shoulder, it is preferred that the shoulderon the edge frame element is not as thick as the panel. This facilitatesgood thermal insulation when the strip retainer is mounted on thepanels, since the gasket and/or strip retainer mounts on the panelsrather than the top hat of the section. The gasket and/or strip retainerforms a gasket seal on the panel, forming a good vapour/smoke barrier.

The edge location and mounting of the panels reduces thermaltransmission by conduction and provides additional strength to thepanel, particularly when suspended from a ceiling. In selectedembodiments the edges of the insulating panels are clamped between thestrip retainers and the edge frame elements, the retainers and frameelements only touching via fasteners along the frame elements, whichprovides rigidity to the panel without thermal transmission byconduction.

In various embodiments of the fourth or fifth aspects, mounting spacersare provided to further insulate the mounting wall or surface.Preferably, the mounting spacers may be mounting blocks for receivingand mounting the elongate frame elements. More preferably, the mountingspacers are suspension hangers to suspend the elongate frame elementsfrom an underside of a mounting surface or deck.

In various embodiments there is provided a tray in which the thermaland/or fire resistant panel is mounted for additional support. The traymay be a sheet of stainless steel. The tray may include small flanges toretain the panel. The flanges may be 17 mm high, for supporting athicker panel, which may be up to 50 mm thick. In one embodiment thetray or sheet of stainless steel may be about 0.45 mm thick.

In various embodiments the panels may be supported on their periphery bychannels. The channels may be of stainless steel. The channels may beC-shaped. The channels may be filled with thermal and/or fire insulatingmaterial acting when assembled against the panel, as a gasket.

In various embodiments, the panel assembly may include an intermediatelayer of insulating material. The intermediate layer may be aluminiumfoil. For example, there may be mounted on one side of a 25 mm panelbody, a layer of aluminium foil, and another 35 mm panel body may bedisposed on the foil side of the 25 mm panel body.

In various embodiments, there is loose fill or a blanket or a boardwhich fills a wall-mounted channel and mounting spacers, between thethermal and/or fire resistant panel and the supporting wall structure.There may be provided a framework or grid or mesh to hold the loose fillor flexible or rigid panels to the wall or supporting structure. Thefill may be intumescent.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a general exploded arrangement of anembodiment of the present technology mounted on a vertical wall, showingcomposite panel, peripheral frame elements, strip retainers, joiner,disc seal cover plate, and mounting spacer.

FIG. 2 is a similar view to that shown in FIG. 1, but the embodiment issuspended from a ceiling or underside of a deck, and therefore there isshown a mounting spacer in the form of suspension elements.

FIG. 3 is an exploded view of a vertex arrangement similar to thoseshown in FIGS. 1 and 2, but the vertex seal plate includes anintumescent disc underneath it.

FIG. 4 is a plan view from underneath of a ceiling-mounted suspensionarrangement, shown in part in FIG. 6.

FIG. 5 is a section view through A-A shown in FIG. 4 and also shownbelow that is a section view of a wall-mounted panel arrangement of apreferred embodiment.

FIG. 6 is a cross-section view (through B-B of FIG. 5) of a suspendedarrangement of the present technology and detail A is a detail of thesecond drawing in FIG. 5, being a wall-mounted panel version of thesuspended panel arrangement shown in FIG. 4.

FIG. 7 is a section view of a panel of one embodiment of the presenttechnology.

FIG. 8 is a section view of a panel of another embodiment of the presenttechnology.

FIG. 9 is a section view of a composite panel of another embodiment ofthe present technology.

FIG. 10 is an isometric view of a general exploded arrangement ofanother embodiment of the present technology mounted on a vertical wall,showing composite panel, peripheral frame elements, strip retainers,joiner; disc seal cover plate; and mounting spacer.

FIG. 11 is a similar view to that shown in FIG. 10, but the embodimentis suspended from a ceiling or underside of a deck, and therefore thereis shown a mounting spacer in the form of suspension elements.

FIG. 12 is an isometric view of a general exploded arrangement ofanother embodiment of the present technology mounted on a vertical wall,showing composite panel, peripheral frame elements, strip retainers,joiner, disc seal cover plate, and mounting spacer.

FIG. 13 is a similar view to that shown in FIG. 12, but the embodimentis suspended from a ceiling or underside of a deck, and therefore thereis shown a mounting spacer in the form of suspension elements.

FIG. 14 is a 30 minute snapshot of the second half of an IMO FTP CodePart 3 fire test where one embodiment is used as the Thermal/Fireinsulation material.

FIG. 15 is a comparison test between two materials during a pilot firetest as mentioned hereinabove, one panel being the thermal/fireinsulating blank and the other being a composite material of oneembodiment of the present technology.

FIG. 16 is a graph of Load vs. Extension which shows adhesion resultsfor Formulation 1 and Formulation 2 compared with a commercial epoxymaterial.

FIG. 17 is a graph showing stress at maximum load (MPa) for wood bindersamples treated with fire resistant compositions based on Formulation 2but with different Epoxy loadings.

FIG. 18 is a graph showing stress at maximum load (MPa) for wood bindersamples treated with fire resistant compositions based on Formulations 1and 2 but with epoxy loadings of 6, 8 and 10 wt %.

FIG. 19 is a graph showing stress at maximum load (MPa) for wood bindersamples treated with fire resistant compositions with different waterproofing agents and silane coupling agents as outlined in Table 6.

FIG. 20 is a graph showing Flexural Load (N) vs. Extension (mm) for woodbinder samples treated with fire resistant compositions according toFormulation 2, but with Epoxy loadings of 6 wt % and 10 wt % incomparison with an Epoxy standard.

FIG. 21 is a graph showing contact angle (degrees) for the fireresistant composition with different water proofing agents and silanecoupling agents as outlined in Table 6.

FIG. 22 is a graph showing contact angle (degrees) with fire resistantcompositions based on Formulations 1 and 2 but with epoxy loadings of 6,8 and 10 wt %.

FIG. 23 is a graph showing viscosity (Pa·s) at 25, 50 and 70° C. forFormulations 1 and 2.

FIG. 24 is a photograph showing no damage apparent on rear side ofpanels after flame testing.

FIG. 25 is a graph showing the viscosity of the fire resistant resinwith varied ratios of metakaolin to sodium silicate.

FIG. 26 is a graph showing contact angle (degrees) with fire resistantcompositions with varying amounts of siloxane and silane.

FIG. 27 is diagram showing the location of unexposed face thermocouples.

FIG. 28 is a graph showing Mean furnace temperature and the standardtime/temperature curve according to Part 3 of IMO 2010 FTP Code.

FIG. 29 is a graph showing Furnace temperatures, standardtime/temperature curve according to Part 3 of IMO 2010 FTP Code andtolerance after 10 min.

FIG. 30 is a graph showing temperature rises recorded on the unexposedface of the specimen and on the aluminium alloy structural core.

FIG. 31 is a graph showing the mean temperature rise recorded on theunexposed face of the specimen.

FIG. 32 is a graph showing the mean temperature rise recorded on thealuminium alloy structural core.

FIG. 33 is diagram showing the location of unexposed face thermocouples.

FIG. 34 is a graph showing the mean furnace temperature and the standardtime/temperature curve according to Part 3 of IMO 2010 FTP Code.

FIG. 35 is a graph showing furnace temperatures, standardtime/temperature curve according to Part 3 of IMO 2010 FTP Code andtolerance after 10 min.

FIG. 36 is a graph showing temperature rises recorded on the unexposedface of the specimen and on the aluminium alloy structural core.

FIG. 37 is a graph showing the mean temperature rise recorded on theunexposed face of the specimen.

FIG. 38 is a graph showing the mean temperature rise recorded on thealuminium alloy structural core.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The present invention relates to a thermal and/or fire resistant panelthat comprises a panel component that has been treated with a fireresistant composition. The fire resistant composition comprises a hybridinorganic polymer (HIP).

In brief, a HIP is an inorganic polymer (such as an aluminosilicatepolymer typically derived from the polycondensation of aluminosilicatesand alkaline solutions) that has been modified to incorporate withintheir structure organic groups. The HIP system was developed by CSIROand is disclosed in U.S. Pat. No. 7,771,686 (the entire disclosure ofU.S. Pat. No. 7,771,686 is hereby incorporated herein by reference).This earlier US patent also suggests that HIP resins may impart enhancedfire and flame resistance when applied to timber. The inventors of U.S.Pat. No. 7,771,686 suggest that this is because during combustion ofwood, wood releases volatile and combustible substances. However, whenwood is coated with a HIP, the release of these volatile and combustiblesubstances is inhibited and as a result flame propagation is reduced.

The inventors have found that a composition containing HIP is alsouseful to impart fire resistance to marine panels. Typically, the marinepanels considered in the context of this invention are those formed fromrefractory materials rather other than wood.

Compositions of a selection of commercially available marine panels areprovided below:

-   -   Marine Board (eg FyreWrap Marine Board LW), manufactured by        Unifrax, has the following composition: amorphous        alkaline-earth-silicates 60-65 wt %, perlite 10-15%, colloidal        silica 10-15%, starch 3-10%.    -   DONACARBO RIGID INSULATION (eg DON-1000, DON-2000, DON-3000,        DON-4000—preferably DON-1000), manufactured by OSAKA GAS        Chemicals Co., Ltd., has the following composition: carbon fibre        90-99.9% and carbonized thermosetting resin 0.1-10%.    -   Superwool Plus Board (eg Board 75, H Board, Board 85, Board LTI,        Board INO), manufactured by Thermal Ceramics, has the following        composition: refractory Alkaline-earth Silicate Ceramic fibres,        silica 1-82%, calcia and magnesia 0.1-43%, alumina, titania, and        zirconia 0.1-6%.    -   Silplate Board (eg Fibrerfrax, Silplate 1308 Structural        Insulating Board), manufactured by UniFrax, has the following        composition: aluminosilicate (refractory ceramic fibres) 90% by        weight, and silica (amorphous) 10% by weight.    -   Silplate 1212S (eg Fibrefrax, Silplate 1212S Structural        insulating boards), manufactured by UniFrax, which has the        following composition: Ca—Mg-silicate fibre 0.1-99%, silica        (amorphous) 0.1-80%, starch 0.1-40%.    -   FibreFrax Duraboard (eg FibreFrax Duraboard products 350ES,        500ES, HD Insulation, LD insulation, RG Insulation, manufactured        by UniFrax, which comprises aluminosilicate (refractory ceramic        fibres), calcined kaolin clay, silica (amorphous), and starch.    -   Other FibreFrax, manufactured by UniFrax and including a        combination of: water, silica (amorphous), aluminosilicate        (refractory ceramic fibre), ethylene glycol and polyethylene        oxide.    -   Thermfrax products (eg Gemcolite ASM FG-165050, Gemcolite LD and        HD and Gemcolite NS), manufactured by Unifrax as refractory        ceramic fibre alumina-silica boards.

The inventors have found that although HIP is useful for improving thefire resistance of such panels (e.g. refractory panels); it has a numberof shortcomings that prevents adoption, particularly in a marinesetting. To address this, the inventors have developed a panel that hasa panel body having at least one surface lined, treated, coated, orimpregnated with a fire resistant composition comprising: a silanecross-linked hybrid inorganic polymer; and a siloxane. The presence ofthe silane and the siloxane are important for enhancing the adhesion ofthe composition to the panel body and provide improved water resistance.Both of these factors are particularly important in environments wherethe panel is exposed to water and/or humidity (e.g. such as in a marineenvironment).

The invention will now be described below in relation to a preferredembodiment.

Turning to FIGS. 1 to 6, there is illustrated a thermal and/or fireresistant panel assembly generally indicated at 10 which includes one ormore thermal and/or fire resistant panels according to a first aspect ofthe invention being insulation panels 20 (which panels 20 areapproximately 1200 mm×2400 mm×20 mm), a locating frame or supportingstructure assembly 30, corner support brackets 39, and coverstrips 32 aconfigured to be mounted on a wall or other surface. In one embodiment,the locating frame may be made out of frame elements 31 being channelwork.

The locating frame 30 is configured to locate at least portions of theone or more thermal insulation panels 20, and the panel retainers 32 arefastened to or otherwise mounted to the channel work 31 for retainingthe insulation panels 20 on the locating frame 30.

In this embodiment, the insulation panel 20 includes a refractory panelbody 22 that has been treated with a fire resistant composition thatcomprises a silane cross-linked hybrid inorganic polymer and a siloxane.

The locating frame 30 includes a plurality of frame elements 31 whichinclude a number of artefacts such as panel edge locating 33 forlocating at least an edge portion of the insulation panels 20.

The frame element 31 includes a recess 34 for receiving an edge portionof a panel, which is in the form of a shoulder 35 against which an edgeportion of the insulation panel 20 may abut in use. The one or moreframe elements 31 includes an integral mounting space 36 for spacing theinsulation panel 20 from the wall on which the panel assembly 10 ismounted. The integral space 36 is created by the top-hat shape 37 offrame element 31 (see FIG. 3).

There is a landing 38 between two spaced-apart shoulders 35 so as tofacilitate fastening of a retainer 32 thereon. The frame element 31 is atop-hat-on-a-top-hat section, the section being formed by being rolledor press-braked. The top hat shape section 37 (as with the elongateretainers described herein) is 0.45 mm thick stainless steel, forlongevity in a marine environment, with space provided under the hatsfor rivet nuts, screws and hanging rods.

There is provided a joiner 39 (see FIG. 2) which joins a plurality ofelongate frame elements 31. The joiner 39 includes recesses forreceiving the ends of the elongate frame elements 31. The joiner is acruciform with four orthogonal recesses to receive four frame ends.

A gasket seal 41 (see FIG. 3) is provided at edges or vertices of theframe elements 31 to retain the panels 20 and to inhibit thermal leakagethrough the assembly. The gasket seal 41 is configured to be mounted onthe panel faces and may be fastened thereon by each retainer 32. Thegasket seal 41 is a disc or plate or elongate shape, or other shape, andmay be formed as a panel of the present invention.

The retainer 32 fastens to the joiner 39 on the opposite side of thepanels to facilitate a sealing contact. The gasket seal 41 is a disc ofinsulation material of about 150 mm in diameter.

More than one kind of retainer 32 is provided, and they fasten orotherwise inter-engage with a respective frame element 31. One kind ofretainer 32 is a disc configured to retain the seal 41 onto one or moreof the frame elements 31. The disc retainer 32 retains the panel 20directly by being mounted abutting thereagainst, and fastened to joiner39 via a screw. Another kind of retainer is an elongate strip 32 a (FIG.3) which abuts the panels along the edge and extends along the frameelement 31 and is fastened or otherwise inter-engaged therewith toreduce thermal conductive contact.

It can be seen in FIG. 3 that the shoulder 35 on the frame element 31 isnot as high as the panel is thick. This facilitates good thermalinsulation when the strip retainer 32 a is mounted on the panels 20.Having the shoulder 35 lower than the panel height provides a goodthermal seal against which the strip retainers 32 a and disc retainers32 can abut, increasing thermal insulation performance since the onlythermal conduction is via the fasteners/screws.

The frame element 31 is mounted on a top hat section being a mountingspacer 50, or alternatively hung from hanging assembly section 50, andmay be integral therewith so as to provide a vapour seal and to reducemanufacturing costs in production.

Further mounting spacers 50 can be provided to provide further space tofurther insulate the mounting wall or surface. The further mountingspacers shown in FIG. 1 are mounting blocks in the form of short, squaretop hats for receiving and mounting the elongate frame elements 31. Theyare short to reduce thermal conduction contact with the mountingsurface.

Further mounting spacers 50 in one form shown in FIG. 2, are suspensionhangers to suspend the elongate frame elements 31 from an underside of amounting surface or deck. It can be seen that the edge frame elements 31are not mounted to the deck; they are mounted to the suspension elementsto reduce thermal transmission by conduction.

The panellised nature of embodiments of the technology and their edgemounts means that if a panel is damaged or needs upgrading ormaintenance, it is a simple matter of removing the fasteners holding theretainers clamping the edges, and removing the panel. Known blanketinsulation, mechanically fastened as it is to the contours of thevessel, is ruined by its removal and maintenance, and the surface ismore difficult to mount fresh blankets.

Turning to FIGS. 7 to 9, a form of insulation panel 20 is shown as panel21 in the form of a board that includes a refractory or insulating panelbody 22, a liner 26 applied to surfaces of the panel body 22. The liner26 comprises the fire resistant composition (e.g. in the form of a curedresin) 24 and a glass fibre/basalt fibre/carbon fibre mat 27. The liner26 is adhered to the panel body 22 via the fire resistant composition24.

In this particular embodiment, the fire resistant composition 24 isapplied to the surface of the panel body 22 in combination with a wovenglass fibre liner 26. An advantage of using liner 26 is that it providesaddition strength in tension along one or more directions in the planeof liner 26.

The liner 26 is applied or affixed to the panel body 22 by receiving thefire resistant composition in the form of a liquid (such as by rolling,brushing, or pouring the fire resistant composition thereon). The liner26 is then adhered to a surface of the panel body 22, and subjected totemperatures and/or pressures to cure the fire resistant composition andform a composite panel 21. In an alternative arrangement, the fireresistant composition is applied to a surface of the panel body 22 inthe form of a liquid and the liner 26 is then applied thereto beforesubjecting the fire resistant composition to temperatures and/orpressures to cure the fire resistant composition to form a compositepanel 21.

It will be appreciated that other embodiments omit the liner 26, orliner 26 may compose of basalt fibre or carbon fibre, or the liner 26may be applied using other techniques. In some embodiments the fireresistant composition is directly applied, such as in the form of aliquid, to the surface of the panel body 22 and then cured such that theinsulation panel 20 is coated or impregnated with the fire resistantcomposition.

The composite panel 21 illustrated also comprises a vapour barrier 29applied to the glass fibre mat surface 27 of the liner 26. The vapourbarrier 29 may be in the form of Venture Tape (a product of the 3MCompany) and/or for example aluminium foil (shown as item 29 a in FIG. 8and FIG. 9).

FIG. 9 shows that the composite panel 21 may also include a layer of anacoustic attenuation material 29 b. Whilst FIG. 9 illustrates a layer onone side of the composite panel 21, the skilled addressee willappreciate that both sides of the composite panel 21 may have a layer ofthe acoustic attenuation material 29 b.

An aesthetic veneer layer 29 a can be added to the face and/or the backof the composite panel 21.

By way of example, to cure the composite panel 21, the composite panel21 is introduced to a heated press and cured at gauge pressures between0.1 and 10 bar and temperatures between 50° C. and 200° C. The panel iscured for 0.1 to 4 hours in the press, and then post-cured at roomtemperature for a few weeks or post-cured in a hot room for a few days.

In one or more forms of the invention, the composite panel 21 has adensity of between about 10 and 1200 kg/m³ and/or has a thermalconductivity profile as set out below:

TABLE 1 Thermal conductivity profile Temperature ° C. ThermalConductivity W/m · K 351 0.05-0.3 600 0.05-0.3 1000 0.05-03 

In FIGS. 10 to 13 a different embodiment of the assembly 10 can be seenas indicated by 10 a and 10 b. In these embodiments the composite panels21 may be formed or mounted in a shallow pan 51 of stainless steel viasteel clips and pins or alternatively fitted within without such covers.The panels are then mounted within the general assembly 30 a and 30 b,on wall-mounted channels 52, directly or indirectly via rolled stainlesssteel stand-off brackets, or suspended channels, which themselves arefilled with insulating material.

Assembly of the fire insulating assembly can be understood from theFigures, and at least from FIGS. 10, 11, 12 and 13. The mounting spacersare mounted on the walls, whether they are suspension hangers orplinths. Then, frame elements 52 are mounted on those mounting spacers,to form frame 30 a and 30 b. The composite panel 21 is located bylocating the edges of the panels 21 on the locating recesses 53 or forembodiment 10 b, are located central to the grid and screwed to thechannel work.

Gaskets 41 are located within the channel work 52 to provide sufficientseal to the panel. Retaining strips 32 and retaining discs are placed onthe panels 21 to form a seal along the seam joins and fastened to theframe elements 52 with screws.

Example 1

Process for Preparing the Fire Resistant Composition

Kaolin clay (1.73 kg) was mixed with D grade sodium silicate solution(3.46 kg) and the resultant mixture of kaolin solution was left todigest until the clay dissolved (approximately 5-15 minutes).

Epoxy Part A (279 g) was mixed with Part B (81 g) and mixed until Part Aand B formed a polymerised epoxy mix.

Silane (300 g), siloxane (150 g) and the polymerised epoxy mix wereadded to the kaolin solution. The resultant mixture was stirred to forma smooth slurry (approximately for 3-5 minutes).

Although the above provides a specific composition, the skilled personwill appreciate that a range of compositions is anticipated. Exemplarycompositional ranges are provided in Table 2 below.

TABLE 2 Compositional ranges for constituent ingredients of fireresistant resin Component Weight Fraction (%) Sodium Silicate 50-65Metakaolin 20-30 Silane Coupling Agent  1-10 Siloxane Water ProofingAgent 0.5-5  Epoxy Part A  4-12 Epoxy Part B 1-4

Example 2 Example Process A

Lengths of Venture tape (aluminium foil tape coated with an adhesivesolvent) were placed adhesive side up on a work surface. The adhesivecover layers were removed from the tape prior to use. A glass fibreweave was placed on top of the adhesive lengths of the tape, so that thetape stuck to the weave. A fire resistant resin comprising at least:silane, HIP, epoxy parts A and B, and siloxane was applied to the glassfibre weave. A Mount Blue insulation panel was placed onto the firstfire resistant resin soaked weave. A second glass fibre weave was thenapplied onto the exposed surface of the Mount Blue insulation panel.Further fire resistant resin was applied to the second glass fibreweave. Finally, aluminium foil was applied over the second HIPS soakedweave. The resultant laminate was held in a press and cured for 90minutes at 70° C. to form a fire resistant glass fibre laminate appliedto a panel body (ie the Mount Blue insulation panel).

Example Process B

Lengths of Venture tape were placed adhesive side up on a work surface.The adhesive cover layers were removed from the tape prior to use. Aglass fibre weave was placed on top of the adhesive lengths of the tape,so that the tape stuck to the weave. A fire resistant resin comprisingat least: silane, HIP, epoxy parts A and B, and siloxane was applied tothe glass fibre weave. Short glass fibres were spread evenly over thefire resistant resin. A Mount Blue insulation panel was placed onto thefirst fire resistant resin soaked weave. A second glass fibre weave wasthen applied onto the exposed surface of the Mount Blue insulationpanel. Further fire resistant resin was applied to the second glassfibre weave. Short glass fibres were spread evenly over the fireresistant resin. Finally, aluminium foil was applied over the secondfire resistant composition soaked weave. The resultant laminate was heldin a press and cured for 90 minutes at 70° C. to form a fire resistantglass fibre laminate applied to a panel body (ie the Mount Blueinsulation panel). The short glass fibres increased the adhesion betweenthe fire resistant resin and the insulation panel.

Example Process C

An insulation board was placed on a work surface. A first glass fibreweave was placed on the board. A fire resistant resin comprising atleast: silane, HIP, epoxy parts A and B, and siloxane was applied to theglass fibre weave. Ventura tape was applied over the surface of thefirst resin soaked weave. The board was then flipped. On the reverseside was placed a second glass fibre weave. Further fire resistant resinwas applied to the second glass fibre weave. Aluminium foil was thenapplied over the second HIPS soaked weave. The resultant laminate washeld in a press and cured for 90 minutes at 70° C. to form a fireresistant panel.

Example Process D

An insulation board was placed on a work surface. A first glass fibreweave was placed on the board. A fire resistant resin comprising atleast: silane, HIP, epoxy parts A and B, and siloxane was applied to theglass fibre weave was applied to the glass fibre weave. Short glassfibres were spread evenly over the fire resistant resin. Ventura tapewas applied over the surface of the resin soaked weave. The board wasthen flipped. On the reverse side was placed a second glass fibre weave.Further fire resistant resin was applied to the second glass fibreweave. Short glass fibres were spread evenly over the fire resistantresin. Finally, aluminium foil was applied over the second fireresistant composition soaked weave. The resultant laminate was held in apress and cured for 90 minutes at 70° C. to form a fire resistant panel.

Example Process E

An insulation board was placed on a work surface. A fire resistant resincomprising at least: silane, HIP, epoxy parts A and B, and siloxane wasapplied to the board. A first glass fibre weave was placed on the resinsoaked board. Ventura tape was applied over the surface of the firstglass fibre weave. The board was then flipped. On the reverse side, fireresistant resin was applied to the board. A second glass fibre weave wasapplied onto the resin. Finally, aluminium foil was applied over thesecond resin soaked weave. The resultant laminate was held in a pressand cured for 90 minutes at 70° C. to form a fire resistant panel.

Example Process F

An insulation board was placed on a work surface. A fire resistant resincomprising at least: silane, HIP, epoxy parts A and B, and siloxane wasapplied to the board. Short glass fibres were spread evenly over thefire resistant resin. A first glass fibre weave was placed on the resinsoaked board. Ventura tape was applied over the surface of the firstglass fibre weave. The board was then flipped. On the reverse side, fireresistant resin was applied to the board. Short glass fibres were spreadevenly over the surface of the fire resistant resin. A second glassfibre weave was applied onto the resin. Finally, aluminium foil wasapplied over the second resin soaked weave. The resultant laminate washeld in a press and cured for 90 minutes at 70° C. to form a fireresistant panel.

Example 3

Resin was prepared according to Example 1 above. A fire resistant paneland non-fire resistant panel were manufactured using the process ofExample 2, Example Process A. The boards prepared ie panel 20 (MarineBoard+HIPS) and blank 22 (Marine Board) had a thickness of 20 mm anddensity of 160 kg/m².

It can be seen from FIG. 15 that in a test rig, with about 950 Celsiuson one side, the performance of the panel 20 (Marine Board+HIPS)outstrips that of the blank 22 (Marine Board) by itself.

Example 4

Resin Evaluation

A first series of experiments were conducted to evaluate the effect ofvarying the type of epoxy resin used to form the HIPS polymer and toinvestigate the use of different silane coupling agents in the resincomposition.

Table 3 below provides the compositional ranges for the fire resistantresin used in this Example.

TABLE 3 Typical composition ranges for the fire resistant resin ReagentRole Typical loading wt % Sodium silicate Reagent to form inorganic50-60 solution backbone with Metakaolin Metakaolin Inorganic clay powderto 25-30 interact with sodium silicate Silane Coupling agent forinorganic  2-10 and organic compounds Epoxy Organic adhesive  5-15Siloxane Water repellent 1-5

The fire resistant resins were prepared according to the method outlinedbelow:

TABLE 4 Fire resistant resin preparation method Step No. Description 1Sodium Silicate Solution weighed 2 Metakaolin added to Sodium Silicate 3Mixture introduced to a Digital IKA RW 20 Stirrer from Crown Scientific4 Stirrer increased to 1500 rpm 5 Stirring continues until Metakaolinhas totally mixed into the Sodium Silicate - 10 minutes 6 Solution isleft to age for 60 minutes 7 Coupling Agent is added - 1 minute 8Siloxane is added - 1 minute 9 Part A and Part B of epoxy are reactedthen added - 5 minutes 10 All additives are placed in a beaker 11 Themixture is introduced to a stirrer. 12 Stirrer speed is increased to1500 rpm and stirring continues until all additives are fully dispersedinto the resin - 10 minutes 13 The resin is removed from the stirrer andis ready for usage

The compositions of the two preferred formulations (referred to asFormulation 1 and Formulation 2 throughout this example) are provided inTable 5 below.

TABLE 5 Composition of Formula 1 and Formula 2 Formulation Epoxy SilaneSiloxane Geopolymer 1 6 wt % 1:0.391 5% 3- 2.5% Wacker 86.5% 2:1 SodiumMegapoxy HX Glycidoxypropyl SIL RES BS66 Silicate:metakaolin PartA:HY2954 trimethoxy silane Part B 2 1:0.29 Hexion 5% 3- 2.5% Wacker86.5% 2:1 Sodium RIMR 935:Hexion Glycidoxypropyl SIL RES BS66Silicate:metakaolin RIMH936 trimethoxy silane

Lap Shear Adhesion

To test the adhesion of the developed fire resistant resins, TasmanianOak wood substrates were employed. Essentially, two overlapping piecesof Tasmanian Oak timber were joined via the resin. The overlappingdistance area between the two pieces of timber was 15 mm. The fireresistant resin was cured overnight in a conventional oven at 70° C. andthen cut into 15 mm strips and tested for adhesion.

The results of an Adhesion Lap shear test are shown in FIGS. 16, 17, 18and 19. FIG. 16 displays raw trace results obtained based on twovariations of the fire resistant resin formulations with an epoxyloading of 10%.

From these adhesion results, it was evident that the fire resistantresin outperformed straight epoxy on a wood substrate. The fireresistant resin should also be applicable on other substrates andcomposite components preferred as part of the final laminate prototypemake-up for application. This make-up comprises of a glass fibre, blueinsulation material supplied by Unifrax and Venture Tape supplied from3M.

Results shown in FIG. 17 of Stress Loads vs Epoxy content informulations indicate considerable difference when going from 5 to 6%epoxy loading and then not a great difference between 6 and 10%. A lowerepoxy loading would not only save cost but could potentially exhibitbetter fire performance. The difference between an epoxy loading of 6and 10% was repeated for Formulation and tested on another candidateprospect, Formulation (FIG. 18).

Improved performance was observed using a loading of 6% epoxy for bothFormulations 1 and 2. At the same time that formulations were beingoptimised for adhesion, the performance of resins incorporatingdifferent water proofing agents and an alternate silane coupling agentwere also analysed. An example of such results is shown in FIG. 19, withaccompanying plot indicators outlined in Table 6 below.

TABLE 6 Resin Formulations No. Epoxy Silane Siloxane 1 100% (MegapoxyHX:Aradur 2954 1:0.391) 2 10% (Megapoxy HX:Aradur 5% 3-Glycidoxypropyl2.5% Silanol terminated 2954 1:0.391) trimethoxy silane polydimethylsiloxane 3 10% (Megapoxy HX:Aradur 2.5% 3-Glycidoxypropyl 2.5% Silanolterminated 2954 1:0.391) trimethoxy silane polydimethyl siloxane 4 10%(Megapoxy HX:Aradur 5% 3-Aminopropyl 2.5% Silanol terminated 29541:0.391) triethoxy silane polydimethyl siloxane 5 10% (MegapoxyHX:Aradur 5% 3-Glycidoxypropyl 1% Protectosil BHN 2954 1:0.391)trimethoxy silane 6 10% (Megapoxy HX:Aradur 5% 3-Glycidoxypropyl 2.5%Protectosil BHN 2954 1:0.391) trimethoxy silane 7 10% (MegapoxyHX:Aradur 5% 3-Glycidoxypropyl 5% Protectosil BHN 2954 1:0.391)trimethoxy silane 8 10% (Megapoxy HX:Aradur 5% 3-Glycidoxypropyl 1%Protectosil WS808 2954 1:0.391) trimethoxy silane 9 10% (MegapoxyHX:Aradur 5% 3-Glycidoxypropyl 2.5% Protectosil WS808 2954 1:0.391)trimethoxy silane 10 10% (Megapoxy HX:Aradur 5% 3-Glycidoxypropyl 5%Protectosil WS808 2954 1:0.391) trimethoxy silane 11 10% (MegapoxyHX:Aradur 5% 3-Glycidoxypropyl 1% Protectosil WS808, 2954 1:0.391)trimethoxy silane 2.5% Protectosil WS808 (3.5 wt % in total) 12 10%(Megapoxy HX:Aradur 5% 3-Glycidoxypropyl 2.5% Wacker SIL RES 29541:0.391) trimethoxy silane BS66 13 10% (Megapoxy HX:Aradur 5%3-Aminopropyl 2.5% Protectosil BHN 2954 1:0.391) triethoxy silane 14 10%(Megapoxy HX:Aradur 5% 3-Aminopropyl 2.5% Protectosil WS808 29541:0.391) triethoxy silane

Two different silane coupling agents were tested. These were3-glycidoxypropyl trimethoxysilane and 3-aminopropyltriethoxy silane.The results indicated that 3-glycidoxypropyl trim ethoxysilane providesbetter adhesion properties than 3-aminopropyltriethoxy silane.

Without wishing to be bound by theory, the inventors are of the viewthat this is due to the presence of the glycidyl group (e.g. epoxygroup) in the 3-glycidoxypropyl trimethoxysilane. The inventors are ofthe view that the lack of an epoxy functional group within the structureof 3-aminopropyltriethoxy silane is responsible for the reduction in itsability to bond as effectively as the 3-glycidoxypropyl trimethoxysilanecompound. The amino functional group (—NH₂) does have reactivepotential, through a lone pair of electrons on the N, but this isthought to be less strong than the epoxy in the surroundingaluminosilicate environment. Furthermore, the epoxy functional group mayprovide a higher frequency of bonding options to the inorganic matrix aswell as being a stronger coupling partner to the organic hardener thatcures the commercial epoxy component.

Flexural Strength

To test flexural strength, 3 layered glass fibre composites werefabricated as outlined in Table 7. The fire resistant resin was thenspread using a squeegee and spatula on both sides of each glass fibrelayer and the system was initially cured for 210 minutes at 70° C.Fabricated laminates were then post cured overnight at 70° C. and cutfor testing.

TABLE 7 Glass laminate fabrication preparation method Step No.Description 1 The fire resistant resin prepared as described above 2 Afirst layer of glass fibre is cut to size - 150 mm × 210 mm 3 The fireresistant resin is applied to the layer of glass fibre as a coating 4The coating is evenly distributed by using a squeegee 5 A second glassfibre is cut and resin is applied 6 The 2 prepared layers are sandwichedtogether 7 The fire resistant resin is applied to the top of sandwichedlayers 1 and 2 8 The fire resistant resin is evenly distributed using asqueegee 9 A third glass fibre layer is prepared 10 The third layer issandwiched onto the 2nd prepared layer 11 The fire resistant resin isapplied to the 3rd layer 12 The fire resistant resin is evenlydistributed by using a squeegee 13 A Teflon film is introduced to thetop and bottom of the prepared layers 14 Top and bottom steel plates areadded 15 The sample is placed into a heated platen press pre-warmed to70° C. 16 The platens are closed and the sample is cured for 210 min at70° C. 17 The laminate is removed and post cured overnight at 70° C. 18The laminate is cut to size for flexural testing (12.7 mm by >60.8 mm)19 The test specimens are tested for flexural strength

An Instron type 5569 (Serial number C5450) was used to test the flexuralstrength of the composites. Testing was performed to ASTM D 790-07 usinga 3 point bend jig. The specimens were 3 mm thick, 12.7 mm wide andgreater than 60.8 mm in length. A 500N Load cell was utilised and thespecimens were tested at a cross-head speed of 1.28 mm/min until themaximum strain in the outer surface of the specimen reached 0.05 mm/mmor if the specimen failed through breakage.

FIG. 20 shows results between Epoxy and HIPS candidate formulations weremore pronounced when measuring for flex. Samples fabricated to measureFlexural Strength consisted of a 3 layer glass fibre system with fireresistant resin in between each layer.

The results indicate that the ductility reduces as the epoxy loading isdecreased. 6% epoxy may still possess enough ductility for the intendedapplication. Impact testing and durability assessments would confirmthis. Other physical advantages of a lower organic epoxy content wouldinclude safer fire performance with less organic volatiles being emittedand a bigger potential for the laminate to maintain its structuralintegrity.

Contact Angle Measurement

The fire resistant resin was coated onto a glass microscope and thencontact angle was measured. A Rame-Hart Manual Contact Goniometer (Model100-00-230, Serial 3107), was employed to determine the level ofhydrophobicity of the fire resistant compositions by measuring thecontact angle of a small water droplet as it sat on the coating'ssurface.

The contact angle measurements are shown in FIG. 21. The descriptors inFIG. 21 correspond with the sample numbers from Table 6 above.

Two types of water proofing agents exhibited excellent contact angleperformance, these were (i) Silanol Terminated Polydimethyl Siloxanefrom Gelest, Inc. and (ii) SILRES BS 66, liquid oligomeric siloxane,from Wacker Chemie AG. The SILRES BS 66 exhibited better durabilityperformance and good miscibility with the other HIPS components.

Upon choosing between an epoxy loading between 6 and 10% with thisfavoured water proofing agent, the contact angles were measured todetermine if there was a difference in performance. Angles around 70°were obtained for all candidate formulation modifications (FIG. 22)indicating little variation when a loading of 2.5% SIL RES BS 66 wasutilised.

Rheology

The resin viscosity and pot-life can provide useful information as tothe flow-ability and application life. A Haake Rheostress 600 fromThermo Electron Corporation (Type 222-1690) was the primary instrumentemployed to measure the viscosity. Resin was subject to a frequency of 1Hertz and a constant stress of 10 Pascal at temperatures of 25, 50 and70° C.

FIG. 23 shows results obtained from Haake Rheostress Rheometermeasurements of resin viscosity at several application temperatures.

The curing time of the fire resistant resin when exposed to a press at70° C. was observed to be around 15 minutes. For 50° C., curing time isjust over 30 minutes. At Room temperature results using the HaakeRheostress Rheometer were inconclusive. It was difficult to find theappropriate instrumentation to measure such properties at thistemperature as HIPS formulations tend to have thixotropic propertiesindicating that the resin maintains flow as it is stirring but once leftwithout agitation, it tends to reside in a cream composition. As themeasuring techniques of other viscosity instruments such as theBrookfield Viscometer and the AND Vibro Viscometer unit require theresin to remain still while the machine components are mobile, readingsobtained were very high, above the limitations of the unit's upperspecifications.

These results demonstrate that pot life can withstand a normal workshift cycle, that is, the resin is still practical to spread and utiliseeven after 6 hours when kept at room temperature.

Panel Testing

Laminate panels were constructed with the freshly prepared fireresistant resin on a flat laboratory bench and then transferred to therelevant curing press to enable the interfaces of each material to bond.Testing of the cured laminates focused on fire resistance performanceand durability under saline conditions. The panel fabricationmethodology is outlined in Table 8 below.

TABLE 8 Panel fabrication preparation method Step No. Description 1 BlueInsulation Panel cut to size 2 Glass fibre cut to cover Blue InsulationPanel 3 The HIPS resin is applied to the fibre 4 The coating is evenlydistributed by using a squeegee or roller 5 The resin totally covers theglass fibre 6 The Venture Tape is placed on the glass fibre and HIPSresin 7 The Panel is flipped over and the glass fibre covers BlueInsulation material 8 The glass fibre is uniformly covered with HIPSresin 9 A second Venture Tape film is applied (if required) 10 Panel isplaced into press with spacer inserts to protect Blue Insulation 11 ThePlatens are closed at a pressure of 0.8 ton 12 The panel is left to curefor 90 minutes at 70° C. 13 The cured panel is removed from the pressand the flashing is cut away 14 The cured panel is placed in its supportbracket

Fire Performance

A fire testing jig was fabricated to measure the fire performance ofpanels fabricated with Formulations 1 and 2 of dimensions 95 mm×95 mm×30mm. This test consisted of mounting a specimen at 90°, then applying aflame for a period of two minutes at a distance of 80 mm. After 2minutes the flame was removed and the samples ability to self-extinguishwas detected as well as the level of flame damage and temperature on thereverse side.

FIG. 24 shows that the most important outcomes to take out of this testis the lack of flammability of the HIPS coated layers and the appearanceof the reverse side of the panel. The flame fails to penetrate throughthe entire panel and the reverse side is still quite cool to touchimmediately after testing. This indicates that the HIPS is potentiallyproviding a barrier between the flame and the blue panel, acting as anobstruction to heat at the layer being exposed. The Venture Tape ishighly flammable and burns continuously when tested on its own. When theflame is exposed to the front Venture Tape side of the composite forFormulations 1 and 2, there is initial ignition. The spread of fire thensubsides once the Venture Tape has burnt away and the HIPS coating seemsto begin absorbing the flame's intensity. When the flame is exposed tothe back HIPS layer, there is no sign of ignition and the front faceremains in pristine condition, maintaining its room temperaturefeatures.

There were very little volatiles being emitted into the atmosphere,especially when the back side HIPS only layer was tested. This is mostprobably due to the largely inorganic component, and therefore lowCarbon amounts present, in the HIPS formulation. A final observation wasthe ability of the HIPS layer to maintain its structural compositionduring and after testing (FIG. 24). There was only minor damage done tothe HIPS coating, with only a slight crack witnessed at the exposuresite, which was probably due to the material becoming brittle uponorganic removal.

Salt Solution Immersion

Fabricated Panels of dimensions 95 mm×95 mm×30 mm and glass laminates ofdimensions 60 mm×60 mm×3 mm were fully immersed in a 3.5% salt solutionfor 42 days to simulate exposure to marine conditions. There was no signof laminate destruction throughout the 42 day test

Example 5

A series of experiments were conducted to evaluate the effect ofchanging the ratio of metakaolin to sodium silicate and to investigatevarying the amount of siloxane added to the composition.

This example is based on the following composition (generally referredto below as the base formulation composition):

-   -   85.7 wt % geopolymer (formed from sodium silicate (57.1 wt %)        and metakaolin (28.6 wt %);    -   6% Epoxy (1:0.29 Hexion Epikote RIM935:Hexion Epikure RIMH936 at        4.65 and 1.35 wt % respectively)    -   0.3 wt % Zinc Oxide;    -   0.5 wt % bluestone colour oxide;    -   2.5 wt % siloxane (Wacker Silres BS 66); and    -   5 wt % silane coupling agent (3-glycidoxypropyltrimethoxy        silane).

Varying the Metakaolin to Sodium Silicate Ratio

FIG. 25 displays viscosity results for the fire resistant resin at thebelow listed ratios:

(1) metakaolin to Sodium Silicate Solution ratio of 1:2 (e.g. the baseformulation)

(2) metakaolin to Sodium Silicate Solution ratio of 1:2.5

(3) metakaolin to Sodium Silicate Solution ratio of 1:3

The results show that a metakaolin to Sodium Silicate Solution ratio of1:3 provides good flow even after 24 hours and is still spreadable after48 hours.

In addition to the above, the adhesion strength, wettability, and impactstrength were also tested at the different metakaolin to sodium silicateratios. The inventors found that:

-   -   a higher loading of sodium silicate slightly increases the        resin's adhesion capabilities especially if curing occurs within        the first 24 hours of the resin's pot life;    -   there was little difference in the measured contact angle        between the different formulations; and    -   there was little difference in the results from a drop dart        impact test.

Varying the Amount of Siloxane and/or Silane

The following fire resistant resin was prepared for the purpose ofproviding a base composition upon which to evaluate the effect of silaneand siloxane content on the water repellence of the composition:

The silane and siloxane contents were adjusted to determine their effecton contact angle. FIG. 26 shows that reducing the amount of silaneand/or siloxane reduces the water repellence of the HIPS resin.Notwithstanding this, the level of water repellence at these lowersilane and/or siloxane levels is still likely to be suitable for marineapplications.

Example 6

Standard Fire Tests

The following example reports results from standard fire tests on aclass A-60 load bearing aluminium bulkhead and a class A-60 load-bearingdeck to which the fire resistant composition has been applied.

TABLE 9 Composition Component Weight Fraction (%) Metakaolin 28.83Sodium Silicate 57.63 Epoxy Part A 4.65 Hexion MGS Epoxy RIM935 EpoxyPart B 1.35 Hexion MGS Hardener RIMH936 Silane 5.003-Glycidoxypropyltrimethoxysilane Siloxane 2.50 SIL RES BS 66

Standard Fire Test 1

The purpose of the test is to determine the fire resistance of a classA-60 load-bearing aluminium bulkhead according to IMO FTP Code 2010 Part3 of Annex 1 of 2010 IMOFTP Code.

Description of Prototype

The aluminium bulkhead was built according to APPENDIX 1 of IMO 2010 FTPCode Part 3, insulated on the stiffened side exposed to the fire withRapid Access Composite PLUS (RAC+) bulkhead structural fire protectionsystem consisting of a composite panels supported by a stainless steelframe work mounted with an air gap of 150 mm between the panels and theship bulkhead. RAC+ panel, having dimension of 2383×1183 mm andthickness of 20 mm, is composed of a layer of non-combustible MarinePanel material having a nominal density of 160 kg/m³ facing on bothsides by means of the fire resistant composition described herein (i.e.a fire resistant composition including at least: silane cross-linked HIPand siloxane) impregnated into a fiberglass cloth and covered with aself-adhesive veneer named VentureClad-1577CW-WML (on the fire-exposedside) or aluminium foil (on the unexposed side). The panels are mountedinside a framework created by 0.45 mm thick stainless steel channels.The framework is fixed to the aluminium bulkhead stiffeners using Omegashaped standoff brackets, having dimension of 50×100×150 mm. Jointsbetween panels are covered with stainless steel cover strips, which areinsulated with 6 mm thick Superwool paper having density of 230 kg/m³and screwed to the framework at nominal 600 mm spacing.

Each intersection of 4 panels is supported by a stainless steel cornersupport bracket and a locking disc, covered with a pressed stainlesssteel cover plate insulated with 6 mm thick Superwool Paper produced byMorgan Thermal Ceramics.

This bulkhead is fitted with an inspection hatch with clear light of900×900 mm, with the hinge fitted on the exposed side, installed in themiddle of a RAC+ panel. The hatch leaf, having dimensions of 900×900 mm,is composed of a stainless steel frame, 0.9 mm thick and, in between,the insulating material. This material is composed of two layers ofMarine Board, 20 mm thick each and having a nominal density of 160kg/m³, externally facing by means of Hybrid Inorganic Polymer System(HIPS) impregnated into a fiberglass cloth and covered with aself-adhesive veneer named VentureClad-1577CW-WML. The frame is composedof a C shaped stainless steel profile having dimensions of 1000×1000×70mm and thickness of 0.9 mm; between the frame and the leaf a gasket typeIntumescent Promaseal-LFC Fire protection laminate, having thickness of3 mm, is fitted. The leaf is equipped with a closure system that acts onthree points, actuated by a removable handle and fitted with one slidingstainless steel rod having diameter of 10 mm.

The details of the tested prototype bulkhead are provided in the tablebelow:

TABLE 10 Panel properties Property Value Nominal density 160 kg/m³Measured density 152 kg/m³ Nominal thickness 20 mm Measured thickness 20mm Measured moisture content 0.91 dry wt % Measured binder content 6.98dry wt %

Test Methodology

The prototype bulkhead was tested in the vertical position with thebulkhead insulated stiffened side exposed to fire. The prototypebulkhead was mounted within a steel restraint frame having a refractoryconcrete lining 50 mm thick. FIG. 27 shows the position of thethermocouples of the unexposed face of the bulkhead.

In FIG. 27, Thermocouples 1, 2, 3, 4, 5 are used to determine surfacetemperature; Thermocouples 6, 7 used to determine stiffener temperature;and Thermocouples 8, 9, 10, 11, 12 used to determine mean aluminium skintemperature on the interface with the insulating material.

Criteria for Classification

The following classification criteria as specified by the test methodwere used:

Insulation: requirements are satisfied if:

a) the average unexposed face temperature increases by not more than140° C. above its initial value;

b) the temperature recorded by any of the individual unexposed facethermocouples is not in excess of 180° C. above its initial temperature;

c) the average aluminium alloy structural core temperature increases bynot more than 200° C. above its initial temperature.

Integrity: requirements are satisfied if:

a) flaming on the unexposed face does not occur;

b) ignition of a cotton wool pad does not occur over cracks and openingsthat lead to the passage of hot gases;

c) a 6 mm-diameter gap gauge cannot be passed through the specimen suchthat the gauge projects into the furnace and cannot be moved a distanceof 150 mm along the gap;

d) a 25 mm-diameter gap gauge cannot be passed through the specimen suchthat the gauge projects into the furnace.

Test Results

The temperatures recorded by the furnace thermocouples are shown in FIG.28 and FIG. 29.

The temperatures recorded by the thermocouples fitted on the unexposedface of the specimen are shown in FIG. 30 and FIG. 31.

The temperatures recorded by the thermocouples fitted on the aluminiumalloy structural core are shown in FIG. 30 and FIG. 32.

The maximum deflection of the specimen was 50 mm.

Flaming on the unexposed face did not occur.

Cracks or apertures on the specimen such to require tests with thecotton wool pad or the gap gauges were not detected.

Observations during the test: at the 21st minute poor contact ofthermocouple TC3; at the 61st minute the test has been interrupted asrequested by the sponsor.

Standard Fire Test 2

The purpose of the test was to determine the fire resistance of a ClassA-60 load-bearing deck according to IMO FTP Code 2010 Part 3 for “A”,“B” and “F” class divisions of Annex 1 of 2010 IMO FTP Code.

Description of Prototype

Aluminium deck built according to APPENDIX 1 of IMO 2010 FTPC Part 3,insulated on the stiffened side exposed to the fire with Rapid AccessComposite 2 (RAC-2) deck structural fire protection system consisting ofa composite panels supported by a stainless steel frame work mountedwith an air gap of 300 mm between the panels and the ship deck. RAC 2panel, having dimension of 2383×1183 mm and thickness of 25 mm, iscomposed of a layer of non-combustible material named Marine Panel(manufacturer Unifrax) having a nominal density of 160 kg/m³ facing onboth sides by means of Hybrid Inorganic Polymer System (HIPS)impregnated into a fiberglass cloth and covered with a self-adhesiveveneer named VenturetapeClad-1577CW (certified as low flame spreadmaterial). The panels are mounted on a stainless steel frameworksuspended below the aluminium deck using Erico Caddy M6Ti clips with a 2mm steel leg installed onto the stiffener flange. The clips are fittedwith M6 steel eye bolt with rubber grommet. 4.76 to 6 mm steel hangingrods are installed between the eye bolt and the frame work at nominal1500 mm centres. The hanging rods are hooked into the steel gridstructure which supports the panels. Additional clips are riveted to thestructure where required. Joints between panels are covered withstainless steel cover strips, which are insulated with 6 mm thickSuperwool Paper (density 230 kg/m³) and screwed to the frame work atnominal 600 mm spacing. Each intersection of 4 panels are supported by astainless steel corner support bracket and locking discs and are coveredwith a pressed stainless steel cover plate insulated with 6 mm thickSuperwool Paper. The three panels having length of 2383 mm are fitted,across the centre of the panels, with a transversal cover stripprofiles, screwed to the joints and insulated with Superwool Paper.

The details of the tested prototype bulkhead are provided in the tablebelow:

TABLE 11 Panel properties Property Value Nominal density 160 kg/m³Measured density 161 kg/m³ Nominal thickness 25 mm Measured thickness 25mm Measured moisture content 0.94 dry wt % Measured binder content 7.17dry wt %

Test Methodology

The prototype deck has been tested in the horizontal position exposingto the fire the deck insulated stiffened side.

The prototype deck was mounted within a steel restraint frame having arefractory concrete lining 50 mm thick.

In the FIG. 33 is shown the position of the thermocouples on theunexposed face of the prototype deck.

Criteria for Classification

The following classification criteria as specified by the test methodwere used:

Insulation: requirements are satisfied if:

a) the average unexposed face temperature increases by not more than140° C. above its initial value;

b) the temperature recorded by any of the individual unexposed facethermocouples is not in excess of 180° C. above its initial temperature;

c) the average aluminium alloy structural core temperature increases bynot more than 200° C. above its initial temperature.

Integrity: requirements are satisfied if:

a) flaming on the unexposed face does not occur;

b) ignition of a cotton wool pad does not occur over cracks and openingsthat lead to the passage of hot gases;

c) a 6 mm-diameter gap gauge cannot be passed through the specimen suchthat the gauge projects into the furnace and cannot be moved a distanceof 150 mm along the gap;

d) a 25 mm-diameter gap gauge cannot be passed through the specimen suchthat the gauge projects into the furnace.

Test Results

The temperatures recorded by the furnace thermocouples are shown in FIG.34 and FIG. 35.

The temperatures recorded by the thermocouples fitted on the unexposedface of the specimen are shown in FIG. 36 and FIG. 37.

The temperatures recorded by the thermocouples fitted on the aluminiumalloy structural core are shown in FIG. 36 and FIG. 38.

The maximum deflection of the specimen was 65 mm.

Flaming on the unexposed face did not occur.

Cracks or apertures on the specimen such to require tests with thecotton wool pad or the gap gauges were not detected.

The present invention provides an improved fire and/or thermal resistantpanel, assembly and kit that is suitable for at least marineapplications and provides superior performance characteristics toexisting systems.

It will be understood that the invention disclosed and defined in thisspecification extends to all alternative combinations of two or more ofthe individual features mentioned or evident from the text or drawings.All of these different combinations constitute various alternativeaspects of the invention.

The invention claimed is:
 1. A thermal and/or fire resistant panelcomprising: a panel body comprising a fire resistant composition,wherein the fire resistant composition comprises: a silane cross-linkedhybrid inorganic polymer; and a siloxane, wherein the silane crosslinked hybrid inorganic polymer is of Formula I:R_(m)[M₂O]_(x)[Al₂O₃]_(y)[SiO₂]_(z)X_(q).PH₂O   Formula I wherein: Rrepresents an organic functional group; M is an alkali metal; X isselected from chlorine and fluorine; m is >0; q is ≥0; x is from 1 to1.6; y is from 1.0; x/y is from 1.0 to 1.6; z is from 3 to 65; z/y is≥1.0; and P is from 3 to 5, and wherein the thermal and/or fireresistant panel comprises less than 20 wt % organic matter, wherein thepanel body is a thermal insulating blank and the thermal insulatingblank comprises: one or more of refractories, fibres, and amorphousalkaline earth silicates, colloidal silica; and starch.
 2. The thermaland/or fire resistant panel of claim 1, wherein the organic functionalgroup R is a silane of the form R¹ _(n)SiO_(4-n), wherein R¹ representsan organic moiety and n is selected from 1, 2, or
 3. 3. The thermaland/or fire resistant panel of claim 1, wherein the compositioncomprises from about 0.5 wt % to about 5 wt % siloxane.
 4. The thermaland/or fire resistant panel of claim 1, wherein the silane cross-linkedhybrid inorganic polymer comprises a glycidyl silane.
 5. The thermaland/or fire resistant panel of claim 1, wherein the panel is a panel ofa refractory material.
 6. The thermal and/or fire resistant panel ofclaim 1, wherein the panel does not include wood.
 7. The thermal and/orfire resistant panel of claim 1, wherein the panel body is laminatedwith a layer of a woven material comprising the fire resistantcomposition.
 8. The thermal and/or fire resistant panel of claim 7,wherein the layer of the woven material is selected from the groupconsisting of: glass fibre, carbon cloth, basalt cloth and steel mesh.9. The thermal and/or fire resistant panel of claim 1, wherein the panelis a marine panel.
 10. The thermal and/or fire resistant panel of claim1, wherein the dimensions of the thermal and/or fire resistant panel arestable under the effects of heat in the range of 0 to 1100° C., whereinthe panel is stable when one or more of the following apply a) thedimensions of the panel are stable; b) no cracks or apertures occur inthe panel; and c) when the heat exposure is on one side of the panel oneor more of the following apply: (i) flaming on the unexposed side of thepanel does not occur; (ii) ignition of a cotton wool pad on theunexposed side of the panel does not occur over cracks and openings thatlead to the passage of hot gases from the heat exposed side of thepanel; (iii) a 6 mm-diameter gap gauge cannot be passed through thepanel such that the gauge projects from the heat exposed side and can bemoved a distance of 150 mm along the gap; and (iv) a 25 mm-diameter gapgauge cannot be passed through the panel such that the gauge projectsfrom the heat exposed side.
 11. The thermal and/or fire resistant panelof claim 1, wherein fire resistant panel has dimensions of up to about1200 mm×up to about 2400 mm×up to about 25 mm.
 12. The thermal and/orfire resistant panel of claim 1, wherein at least one surface of thepanel is lined, treated, coated or impregnated with the fire resistantcomposition.
 13. The thermal and/or fire resistant panel of claim 1,wherein the panel body is a laminate and the laminate shows no sign oflaminate destruction after 42 days immersion in 3.5% salt solution. 14.The thermal and/or fire resistant panel of claim 1, wherein the siloxaneis one or more of liquid oligomeric siloxane, silanol terminatedpolydimethyl siloxane, isobutyltriethoxysilane, and tripotassiumpropylsilane triolate.
 15. The thermal and/or fire resistant panel ofclaim 1, wherein the thermal insulating blank is a compressed fibreboard of refractory fibres.
 16. The thermal and/or fire resistant panelof claim 1, wherein the thermal insulating blank has a thermalconductivity value of less than 0.3 W/m·K at temperatures at 1000° C. orless.
 17. The thermal and/or fire resistant panel of claim 1, whereinthe panel further comprises a vapour barrier layer on at least one ormore faces of the panel body.